Watts HKFC20 Series User manual

Series HKFC20

Pump mixing valve group with

electrical fix point control for heating systems

Installation and Operating Manual

(translated from the original operating manual)

WattsWater.eu

2HKFC20-IM-DE-W-UK-04-2022-Rev.1 | Part no. 10084532

EN ENGLISH

1 General information

1.1 Important information

The operator is responsible for ensuring

adherence to the local laws and regulations

(e.g. accident prevention regulations, etc.).

Incorrect operation or operating the pump

group contrary to the specifications shall

void all rights to any warranty claim.

This Installation and Operating Manual

• is a component of the pump group

• contains instructions and information on safe and correct

installation and commissioning of the pump group

• must be available to all users throughout the entire service

life of the pump group

• is intended for trained personnel who are familiar with the

applicable standards and provisions and, in particular, with

the relevant safety concepts and the operation and mainte-

nance of the pump group

• is protected by copyright and may not be changed without

the manufacturer’s permission

• may not be made accessible to non-authorized personnel;

neither in original form nor as a copy

1.2 Product conformity

A Declaration of Conformity according to the Machinery

Directive 2006/42/EC has been issued for this pump group

product.

1.3 Product features

• stable mounting bracket including mounting hardware

• patented 3-piece EPP insulating shell

• all connections to the system with 1" male thread and flat

sealing

• compact, space-saving design

Contents

1 General information ................................... 2

1.1 Important information ..................................................... 2

1.2 Product conformity .........................................................2

1.3 Product features .............................................................2

2 Safety ........................................................... 3

2.1 Presentation of the safety instructions............................3

2.2 Important safety instructions .......................................... 3

2.3 Intended use ..................................................................3

2.4 Foreseeable misuse .......................................................3

2.5 Responsibilities of the operator ......................................3

2.6 Groups of persons .........................................................3

3 Technical data ............................................. 4

4 Pressure loss curve ................................... 5

5 Overall dimensions ..................................... 5

6 Components overview ............................... 6

7 Installation and commissioning ............... 6

7.1 Installation diagram ........................................................6

7.2 Installation ......................................................................7

7.3 Initial Commissioning......................................................7

7.4 Thermometer handle position ........................................7

7.5 Exchanging the supply and return line ...........................8

8 Maintenance ............................................... 9

8.1 Annual maintenance intervals .........................................9

8.2 Replacement of wear parts ............................................ 9

8.3 Disassembling the circulation pump .............................10

8.4 Installation of the circulation pump ............................... 10

8.5 Disassembling the 3-way mixer .................................... 11

8.6 Installing the 3-way mixer ............................................. 11

8.7 3-way mixer motor setting ............................................ 11

9 Disposal ..................................................... 12

9.1 Return shipment to the manufacturer ........................... 12

9.2 Reporting to administrative bodies and manufacturer .. 12

10 Guarantee .................................................. 12

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2 Safety

2.1 Presentation of the safety instructions

DANGER indicates an imminent danger

that may cause serious physical injury or

death without the corresponding safety

precautions.

WARNING indicates a danger arising

through incorrect behavior that may cause

serious physical injury or death (e.g. misuse,

disregarding notices, etc.).

CAUTION indicates a potentially dangerous

situation that may cause minor or slight

injuries without the corresponding safety

precautions.

NOTICE indicates a situation that may cause

material damage without the corresponding

precautions.

2.2 Important safety instructions

• Carefully read through these operating instructions.

• Only connect the pump group to a power source that

corresponds to the mains voltage specified on the rating

plate of the pump group.

• The power supply to the pump group must be

disconnected prior to maintenance, cleaning and repair

work.

• Only trained specialist personnel are permitted to perform

maintenance, cleaning and repair work.

• The pump group must not be used if it is damaged or if the

pump group is no longer operating correctly. In this case,

contact your specialist dealer immediately.

• Adhere to the maintenance instructions and intervals.

• Protect the pump group from the influences of weather.

• Never use the pump assembly outdoors.

• The machine is only permitted to be used for the purpose

for which it was intended.

2.3 Intended use

The pump group is used to distribute heating water in heating

systems.

The pump group is completely pre-assembled and designed

for mounting on a wall.

The pump group is not intended to be operated by people

(including children) with physical, sensory or mental

disabilities, nor by people with insufficient experience or

previous knowledge.

2.4 Foreseeable misuse

The following is considered to be foreseeable misuse:

• operating the pump group contrary to the specifications

• improper use of the pump group

• modifications to the pump group that were not agreed with

the manufacturer

• use of replacement or wear parts that were not approved

by the manufacturer

• operating the pump group outdoors (parts and

components are not UV resistant)

2.5 Responsibilities of the operator

The operator must ensure that:

• the pump group is only used for its intended purpose

• the pump group is installed, operated and maintained

according to the specifications in the Installation and

Operating Manual

• the pump group is only operated according to local

regulations and occupational health and safety regulations

• all precautionary measures have been carried out to avoid

dangers originating from the pump group

• all precautionary measures for first aid treatment and

firefighting have been carried out

• only authorized and trained users have access to the pump

group and operate it

• users have access to this Installation and Operating

Manual at all times

2.6 Groups of persons

Only qualified persons may operate the pump group or

perform service and maintenance work.

User

A user is deemed to be qualified if they have read these

operating instructions and understood the potential risks

associated with incorrect behavior.

Fitter/commissioner

Due to their specialist training and knowledge, and taking into

consideration the applicable standards, provisions, regulations

and laws, a fitter/commissioner is capable of performing work

on the pump group and recognizing and avoiding potential

risks.

4HKFC20-IM-DE-W-UK-04-2022-Rev.1 | Part no. 10084532

EN ENGLISH

3 Technical data

Hydraulic performance data

Max. operating pressure 6 bar

Ambient temperature -2 °C to +40 °C (observe pump specification!)

Operating temperature +2 °C to +90 °C (observe pump specification!)

Opening pressure of gravity brake 10 mbar

Kvs bypass 6.3

Temperature display area 0 - 120 °C

Temperature setting area 20 - 80 °C

Media Water / water-glycol mixtures according to VDI 2035/ÖNORM H 5195

Electrical connection

Power supply See separate pump documentation!

Dimensions

Width x height x depth with EPP shell 240 x 310 x 217 mm

Axis center distance 90 mm

Sealing surfaces distance 293 mm

Connections to pipe network

1"AG, male thread, flat sealing (55 Nm)

Tightening torques for screwed connections

¾" 35 Nm

1" 55 Nm

Material

Fittings brass CW617N

Pipes stainless steel Ø33 mm

Plastics impact resistant and temperature resistant

Flat seals AFM 34/2

Bypass pipe brass CW617N

Gravity brake POM. NBR. stainless steel

O-rings EPDM

Insulation EPP

Retaining bracket Spring steel

Wall bracket Galvanized steel sheet

Circulation pump

The technical data on the circulating pumps can be found in the respective pump documentation.

Motor incl. controller

The technical data on the motors can be found in the respective motor documentation.

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ENGLISH

4 Pressure loss curve

100

1.000

100 10.000 100.000

Druckverlust [mbar]

1.000

Durchﬂuss [L/h]

Flow rate [l/h]

Pressure loss [mbar]

5 Overall dimensions

310

217

729310

232

G1" G1"

116 116

6HKFC20-IM-DE-W-UK-04-2022-Rev.1 | Part no. 10084532

EN ENGLISH

6 Components overview

1Wall bracket

2Ball valve with gravity brake 1) (supply)

3Immersion sleeve for supply sensor of the motor

4Circulation pump

53-way-mixer

6Motor incl. controller

7Bypass connection pipe

8Ball valve (return)

ASupply outlet (heating circuit)

BReturn inlet (heating circuit)

CReturn outlet (boiler circuit)

DSupply inlet (boiler circuit)

1) see 7.4 on page 7

7 Installation and commissioning

Electricity!

Risk of death from electric shock.

• Work on parts carrying live voltage must only

be carried out by trained electricians.

• Disconnect the power supply of the system

and secure it against being switched back on

before carrying out any installation, mainte-

nance, cleaning or repair work.

The installation and commissioning of the

pump group must only be carried out by

trained personnel who have been authorized

by the manufacturer.

Take care to adhere to the specified

installation positions and flow directions of

the individual components to be replaced

during repair or replacement work!

Material damage!

A water hammer may occur if the stop valve

is opened quickly.

• Always open the stop valve slowly and in a

controlled way.

7.1 Installation diagram

116 116

47,5

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7.2 Installation

ll screw fittings must be checked and tightened if

required prior to installation and commissioning!

Torque:

• ¾" fittings 35 Nm

• 1" fittings 55 Nm

Voraussetzungen

Requirement

• The valves are pre-installed at the factory but must be

checked for leaks during commissioning (pressure test)

1. Remove the front panel of the pump group.

2. Drill hole according to the size of the screws and wall

plugs.

3. Insert wall plugs.

4. Screw the hanger bolt into the wall plugs.

9The hanger bolt must project at least 50 mm out of

the wall.

5. Place the pump group to the wall in a vertical installation

position (see "„7.1 Installation diagram“ on page 6).

6. Secure the pump assembly with the nut on the hanger bolt.

7. Remove the thermometer handles and dismount the

intermediate insulation.

8. Connect the supply and return lines and check that all

screw connections are tight.

7.3 Initial Commissioning

Requirement

• The pump group is completely assembled.

Connection of the power supply

1. Connect the power supply (see separate pump

documentation).

9The pump group switches on automatically after being

connected to the power supply.

2. Vent the heating system.

The pump group must be switched off

during the ventilation process!

3. Mount intermediate insulation and attach thermometer grips.

4. Mount the front panel of the pump group.

Settings of the motor and controller

Set-point temperature is preset to 50 °C.

9For further information on the motor and controller,

please refer to the enclosed instructions.

7.4 Thermometer handle position

A B C

AOperation position: Gravity brake ready to work; ball

valve open

BEmpty: Gravity brake open; ball valve ½ open (only

included in the supply line)

CService position: Ball valve closed

8HKFC20-IM-DE-W-UK-04-2022-Rev.1 | Part no. 10084532

EN ENGLISH

7.5 Exchanging the supply and return line

The flow is on the right side.

1. Disconnect the power supply and secure it against being

switched on again.

2. Disassemble motor from 3-way mixer.

3. Remove lines from bracket and detach connecting tube

from 3-way mixer.

4. Exchange the lines.

The supply line is now on the left side.

5. Loosen the connection to the ball valve, turn the return

pipe and tighten the connection to the ball valve again.

6. Release the end cap from the 3-way mixer and close the

opposite side with it.

7. Connect the connection tube to the 3-way mixer and insert

the cords into the holder.

8. Reorient the mixer rotary plug valve and mount the motor.

9Observe the separate operating instructions of the

motor.

9Check the pump group for leaks.

4 5 6

1 2 3

7 8

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8 Maintenance

Electricity!

Only perform maintenance work on the

pump group if the voltage supply has been

disconnected.

Hot water!

Severe scalds possible.

Do not reach into the hot water when

emptying the pump group.

Ensure that the pump group has cooled

down before carrying out maintenance,

cleaning and repair work.

Install a suitable scald protection device

at every tapping point (for example, safety

shut-off valve or thermostat mixer tap).

More detailed information on scald

protection can be found in DIN 1988, sheet

2, clause 4.2.

Hot surfaces!

Serious burns possible.

Do not touch the pipelines or the

components during operation.

Ensure that the pump group has cooled

down before carrying out maintenance,

cleaning and repair work.

Wear heat-resistant safety gloves if it

is necessary to carry out work on hot

components.

The maintenance of the pump group must

only be carried out by trained personnel who

have been authorized by the manufacturer.

8.1 Annual maintenance intervals

1. General visual inspections

• Check the station for leaks and retighten sealing connec-

tions or replace seals, as required.

2. Functional checks

• Check that settings and operating and performance

parameters are set correctly.

• Check flow noise during operation.

• Ask users if there are any noticeable problems.

3. Ball taps

• Check that stop valves and ball taps can move freely.

4. Pump

• Pay attention to the noise of the pump.

5. 3-way mixer

• Check 3-way mixer for function.

6. Motor

• Check the motor for function.

7. Actions following maintenance work

• Check that all screw fittings that were unscrewed have

been retightened and retighten if necessary.

• Remove all tools, materials and other equipment used from

the working area.

• Vent the system.

8.2 Replacement of wear parts

Please note that the pump group contains parts that, for

technical reasons, are subject to wear depending on the

intensity of use, even if the specified care and maintenance

have been observed.

This especially applies to mechanical parts and parts that

could come into contact with water and steam, for example,

hoses, seals, valves, etc.

By their nature, defects as the result of wear do not represent

a fault and therefore are not covered by the warranty or the

guarantee. Nevertheless, these defects and malfunctions

must only be remedied by trained specialist personnel.

Contact your specialist dealer for this.

10 HKFC20-IM-DE-W-UK-04-2022-Rev.1 | Part no. 10084532

EN ENGLISH

8.3 Disassembling the circulation pump

1. Disconnect the power supply and secure it against being

switched on again.

2. Remove the front panel of the pump group.

3. Close all stop valves.

4. Disassemble thermometer handles and intermediate

insulation.

5. Disconnect the wiring of the circulation pump.

6. Release the fastening nuts (X) and remove the circulation

pump.

Risk of heavy scalding from hot water!

• Allow the pump group to cool before

servicing.

• Do not reach into the hot medium when

emptying.

8.4 Installation of the circulation pump

1. Replace damaged or defective seals if necessary.

2. Insert the circulation pump and tighten the nuts (X) (for

tightening torques see “Technical data” on page 4).

3. Connect the wiring of the circulation pump.

4. Slowly open the ball valves by turning the thermometer

handle.

5. Slowly pressurize the pump assembly and vent the system

if necessary.

6. Check the pump group for leaks.

7. Restore the power supply to the pump group.

8. Disassemble the thermometer handles.

9. Install the intermediate insulation, the thermometer

handles, and the front panel.

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8.5 Disassembling the 3-way mixer

1. Disconnect the power supply and secure it against being

switched on again.

2. Remove the front panel of the pump group.

3. Close all stop valves.

4. Disassemble thermometer handles and intermediate

insulation.

5. Move the mixer rotary plug valve to center position by

manual adjustment of the motor.

6. Disassemble the motor (Pos. B, the assembly/disassembly

of the motor can be found in the respective manufactur-

er's instructions).

7. Remove the mixer (pos. A) by loosening the union nuts.

9The assembly / disassembly of the motor can be

found in the respective manufacturer’s manual.

8.6 Installing the 3-way mixer

1. Replace damaged or defective seals if necessary.

2. Install the 3-way mixer (B) and tighten the union nuts (for

tightening torques see “Technical data” on page 4).

3. Mount the motor (A).

4. Slowly open the ball valves by turning the thermometer

handle.

5. Restore the power supply to the pump group.

6. Disassemble the thermometer handles.

7. Install the intermediate insulation, the thermometer han-

dles, and the front panel.

9The assembly / disassembly of the motor can be

found in the respective manufacturer’s manual.

8.7 3-way mixer motor setting

Mixer closed Mixer open

The descriptions and photographs contained in this product speciﬁcation sheet are supplied by way of information only and are not binding.

Watts Industries reserves the right to carry out any technical and design improvements to its products without prior notice.”

Warranty: All sales and contracts for sale are expressly conditioned on the buyer’s assent to Watts terms and conditions found on its website at www.wattswater.eu/gtc/

Watts hereby objects to any term, different from or additional to Watts terms, contained in any buyer communication in any form, unless agreed to in a writing signed by an ofﬁcer of Watts..

Watts Industries Deutschland GmbH

Godramsteiner Hauptstr. 167 • 76829 Landau • Deutschland

Tel. +49 6341 9656 0 • Fax +49 6341 9656 560

WIDE@wattswater.com • www.wattswater.de

HKFC20-IM-DE-W-UK-04-2022-Rev.1 | Part no. 10084532

9 Disposal

Potential contamination of the environment

and groundwater due to improper disposal!

The regulations and guidelines of the

legislature in the country of operation

must be complied with when disposing of

components and operating materials.